Bolt removal template and methods of use thereof

Abstract

Embodiments relate to a bolt removal template that can be used remove failed bolts from Doser Valve mounting bolt holes of a DEF fuel tank or other suitable bolt holes. The bolt removal template comprises a plate and an expandable flange. The plate can have a plurality of apertures. The plate can have a top and bottom. The flange can be positioned on the bottom of the plate and adjacent to one of the apertures.

1 . A system comprising:
 a DEF fuel tank housing comprising a fuel line and a bolt hole;   a bolt removal template comprising:
 a plate, the plate having a plurality of apertures, the plate having a top and bottom; and 
 a flange, the flange positioned on the bottom of the plate and adjacent to one of the apertures; 
   wherein the plate is configured to engage with the DEF fuel tank housing; and   wherein, when the plate is engaged with the DEF fuel tank housing, the flange is positioned inside the fuel line.   
     
     
         2 . The system of  claim 1 , wherein the plurality of apertures includes four apertures. 
     
     
         3 . The system of  claim 1 , wherein at least one aperture has an internal threaded portion. 
     
     
         4 - 5 . (canceled) 
     
     
         6 . The system of  claim 1 , further comprising:
 a threaded bolt positioned within the flange;   a mechanical fastener configured to threateningly engage the bolt;   wherein engaging the plate with the DEF fuel tank housing involves actuating the mechanical fastener.   
     
     
         7 . The system of  claim 1 , wherein the flange comprises an annular member having a notch formed in a peripheral portion of the annular member. 
     
     
         8 . The system of  claim 1 , wherein the flange comprises material capable of elastic deformation. 
     
     
         9 . The system of  claim 1 , wherein the flange comprises nylon. 
     
     
         10 . The system of  claim 6 , wherein actuating the mechanical fastener causes the flange to expand in a direction that is radial to a longitudinal axis of the threaded bolt. 
     
     
         11 . The system of  claim 10 , wherein expansion of the flange secures the template to the DEF fuel tank housing and/or at least partially obstructs the fuel line. 
     
     
         12 . The system of  claim 8 , wherein expansion of the flange holds the plate stationary relative to the DEF fuel tank housing. 
     
     
         13 . The system of  claim 1 , wherein one aperture is aligned with the bolt hole. 
     
     
         14 . The system of  claim 1 , wherein:
 the plurality of apertures includes a first bolt aperture, a second bolt aperture, a third bolt aperture, and a fuel line aperture;   wherein:
 each of the first bolt aperture, the second bolt aperture, and the third bolt aperture is positioned on the plate so as to align with a first bolt hole, a second bolt hole, and a third bolt hole, respectively, of the DEF fuel tank housing when the plate bottom is placed adjacent to the DEF fuel tank housing; and 
 the fuel line aperture is positioned on the plate so as to align with a fuel line of the DEF fuel tank housing when the plate bottom is placed adjacent to the DEF fuel tank housing. 
   
     
     
         15 . A method for removing a failed bolt from a fuel tank housing with a bolt removal template, the fuel tank housing having a fuel line and a bolt hole, the bolt removal template comprising: a plate, the plate having a plurality of apertures, the plate having a top and bottom; and a flange, the flange positioned on the bottom of the plate and adjacent to one of the apertures, the method comprising:
 placing the plate adjacent to the fuel tank housing such that the flange is positioned inside the fuel line and one aperture is aligned or co-registered with the bolt hole, the bolt hole containing a failed bolt;   inserting a drill bit through the aligned or co-registered aperture so as to make contact with the failed bolt;   allowing the bolt removal template to maintain the drill bit in proper alignment before, during, and/or after actuation of the drill bit;   wherein actuating the drill bit involves causing the drill bit to rotate about an axis of the drill bit and/or to move in a direction parallel to the axis of the drill bit;   wherein proper alignment includes: maintaining the drill bit at an orientation that is co-axial with the bolt hole and/or preventing the drill bit from moving laterally so as to misalign or not co-register with the bolt hole; and   actuating the drill bit.   
     
     
         16 . The method of  claim 15 , further comprising securing the plate to the fuel tank housing. 
     
     
         17 . The method of  claim 16 , wherein securing the plate to the fuel tank housing forces the one aperture to be aligned or co-registered with the bolt hole during actuation of the drill bit. 
     
     
         18 . The method of  claim 15 , wherein actuating the drill bit bores out at least a portion of the failed bolt. 
     
     
         19 . The method of  claim 15 , wherein actuating the drill involves actuating a drill in mechanical connection with the drill bit. 
     
     
         20 . The method of  claim 15 , further comprising causing the flange to expand to secure the plate to the fuel tank housing and/or at least partially obstruct the fuel line. 
     
     
         21 . The system of  claim 1 , wherein the DEF fuel tank housing is configured to receive a doser valve via the bolt hole.